Merge branch 'dev' into dev

source/Core/BSP/MHP30/configuration.h

@@ -103,8 +103,8 @@
 #define DETAILED_IDLE      0 // 0: Disable 1: Enable - Default 0
 
 // Due to large thermal mass of the PCB being heated we need to pull this back a bit
-#define THERMAL_RUNAWAY_TIME_SEC 45
-#define THERMAL_RUNAWAY_TEMP_C   3
+#define THERMAL_RUNAWAY_TIME_SEC 20
+#define THERMAL_RUNAWAY_TEMP_C   2
 
 #define CUT_OUT_SETTING          0  // default to no cut-off voltage
 #define RECOM_VOL_CELL           33 // Minimum voltage per cell (Recommended 3.3V (33))

source/Core/BSP/Miniware/configuration.h

@@ -63,8 +63,13 @@
  * OLED Brightness
  *
  */
-#define MIN_BRIGHTNESS     0   // Min OLED brightness selectable
-#define MAX_BRIGHTNESS     100 // Max OLED brightness selectable
+#if defined(MODEL_TS101)
+  #define MIN_BRIGHTNESS     1   // Min OLED brightness selectable
+  #define MAX_BRIGHTNESS     101 // Max OLED brightness selectable
+#else
+  #define MIN_BRIGHTNESS     0   // Min OLED brightness selectable
+  #define MAX_BRIGHTNESS     100 // Max OLED brightness selectable
+#endif
 #define BRIGHTNESS_STEP    25  // OLED brightness increment
 #define DEFAULT_BRIGHTNESS 25  // default OLED brightness
 
@@ -104,7 +109,7 @@
 #define DETAILED_IDLE      0 // 0: Disable 1: Enable - Default 0
 
 #define THERMAL_RUNAWAY_TIME_SEC 20
-#define THERMAL_RUNAWAY_TEMP_C   10
+#define THERMAL_RUNAWAY_TEMP_C   3
 
 #define CUT_OUT_SETTING          0  // default to no cut-off voltage
 #define RECOM_VOL_CELL           33 // Minimum voltage per cell (Recommended 3.3V (33))
@@ -214,6 +219,7 @@
 #define TEMP_NTC             1
 #define ACCEL_I2CBB1         1
 #define POW_EPR              1
+#define TIP_TYPE_SUPPORT     1 // Support for tips of different types, i.e. resistance
 #define AUTO_TIP_SELECTION   1 // Can auto-select the tip
 #define TIPTYPE_T12          1 // Can manually pick a T12 tip
 #define HAS_POWER_DEBUG_MENU

source/Core/BSP/Pinecil/configuration.h

@@ -104,7 +104,7 @@
 #define DETAILED_IDLE      0 // 0: Disable 1: Enable - Default 0
 
 #define THERMAL_RUNAWAY_TIME_SEC 20
-#define THERMAL_RUNAWAY_TEMP_C   20
+#define THERMAL_RUNAWAY_TEMP_C   3
 
 #define CUT_OUT_SETTING          0  // default to no cut-off voltage
 #define RECOM_VOL_CELL           33 // Minimum voltage per cell (Recommended 3.3V (33))

source/Core/BSP/Pinecilv2/configuration.h

@@ -105,7 +105,7 @@
 #define DETAILED_IDLE      0 // 0: Disable 1: Enable - Default 0
 
 #define THERMAL_RUNAWAY_TIME_SEC 20
-#define THERMAL_RUNAWAY_TEMP_C   20
+#define THERMAL_RUNAWAY_TEMP_C   3
 
 #define CUT_OUT_SETTING          0  // default to no cut-off voltage
 #define RECOM_VOL_CELL           33 // Minimum voltage per cell (Recommended 3.3V (33))
@@ -155,6 +155,7 @@
 #define POW_EPR                    1
 #define ENABLE_QC2                 1
 #define MAG_SLEEP_SUPPORT          1
+#define TIP_TYPE_SUPPORT           1 // Support for tips of different types, i.e. resistance
 #define AUTO_TIP_SELECTION         1 // Can auto-select the tip
 #define TIPTYPE_T12                1 // Can manually pick a T12 tip
 #define DEVICE_HAS_VALIDATION_SUPPORT

source/Core/BSP/Sequre/configuration.h

@@ -133,7 +133,7 @@
 #define TEMP_uV_LOOKUP_S60
 #define USB_PD_VMAX                     12  // Maximum voltage for PD to negotiate
 #define THERMAL_RUNAWAY_TIME_SEC 20
-#define THERMAL_RUNAWAY_TEMP_C   10
+#define THERMAL_RUNAWAY_TEMP_C   3
 #define USB_PD_TIMEOUT     1   // Default Timeout for USB-PD Protocol negotiation in x100ms
 
 #define HARDWARE_MAX_WATTAGE_X10 600
@@ -168,7 +168,7 @@
 #define TEMP_uV_LOOKUP_S60
 #define USB_PD_VMAX                     20  // Maximum voltage for PD to negotiate
 #define THERMAL_RUNAWAY_TIME_SEC 20
-#define THERMAL_RUNAWAY_TEMP_C   10
+#define THERMAL_RUNAWAY_TEMP_C   3
 #define USB_PD_TIMEOUT     1   // Default Timeout for USB-PD Protocol negotiation in x100ms
 
 #define HARDWARE_MAX_WATTAGE_X10 600
@@ -225,8 +225,8 @@
 
 #define TIP_THERMAL_MASS         30 // X10 watts to raise 1 deg C in 1 second
 #define TIP_THERMAL_INERTIA      10 // We use a large inertia value to smooth out the drive to the tip since its stupidly sensitive
-#define THERMAL_RUNAWAY_TIME_SEC 60
-#define THERMAL_RUNAWAY_TEMP_C   3
+#define THERMAL_RUNAWAY_TIME_SEC 30
+#define THERMAL_RUNAWAY_TEMP_C   2
 
 #define COPPER_HEATER_COIL 1  // Have a heater coil that changes resistance on us
 #define TIP_RESISTANCE     52 // PCB heater, measured at ~19C. Will shift by temp a decent amount

source/Core/Inc/Settings.h

@@ -123,6 +123,7 @@ typedef enum {
  * Some devices allow multiple types of tips to be fitted, this allows selecting them or overriding the logic
  * The first type will be the default (gets value of 0)
  */
+#ifdef TIP_TYPE_SUPPORT
 typedef enum {
 #ifdef AUTO_TIP_SELECTION
   TIP_TYPE_AUTO, // If the hardware supports automatic detection
@@ -142,7 +143,15 @@ typedef enum {
   // #endif
   TIP_TYPE_MAX, // Max value marker
 } tipType_t;
-uint8_t getUserSelectedTipResistance(); // returns the resistance matching the selected tip type or 0 for auto
+#else
+typedef enum {
+  TIP_TYPE_AUTO = 0, // value for the default case
+  TIP_TYPE_MAX  = 0, // marker for settings when not supported
+} tipType_t;
+#endif /* TIP_TYPE_SUPPORT */
+
+// returns the resistance matching the selected tip type or 0 for auto and when not supported
+uint8_t getUserSelectedTipResistance();
 
 // Settings wide operations
 void saveSettings();
@@ -162,5 +171,7 @@ void setSettingValue(const enum SettingsOptions option, const uint16_t newValue)
 // Special access helpers, to reduce logic duplication
 uint8_t     lookupVoltageLevel();
 uint16_t    lookupHallEffectThreshold();
+#ifdef TIP_TYPE_SUPPORT
 const char *lookupTipName(); // Get the name string for the current soldering tip
+#endif /* TIP_TYPE_SUPPORT */
 #endif                       /* SETTINGS_H_ */

source/Core/Src/Settings.cpp

@@ -298,16 +298,12 @@ uint8_t lookupVoltageLevel() {
   }
 }
 
+#ifdef TIP_TYPE_SUPPORT
 const char *lookupTipName() {
   // Get the name string for the current soldering tip
   tipType_t value = (tipType_t)getSettingValue(SettingsOptions::SolderingTipType);
 
   switch (value) {
-#ifdef AUTO_TIP_SELECTION
-  case tipType_t::TIP_TYPE_AUTO:
-    return translatedString(Tr->TipTypeAuto);
-    break;
-#endif
 #ifdef TIPTYPE_T12
   case tipType_t::T12_8_OHM:
     return translatedString(Tr->TipTypeT12Long);
@@ -319,7 +315,7 @@ const char *lookupTipName() {
     return translatedString(Tr->TipTypeT12PTS);
     break;
 #endif
-#ifdef TIPTYE_TS80
+#ifdef TIPTYPE_TS80
   case tipType_t::TS80_4_5_OHM:
     return translatedString(Tr->TipTypeTS80);
     break;
@@ -328,13 +324,19 @@ const char *lookupTipName() {
   case tipType_t::JBC_210_2_5_OHM:
     return translatedString(Tr->TipTypeJBCC210);
     break;
+#endif
+#ifdef AUTO_TIP_SELECTION
+  case tipType_t::TIP_TYPE_AUTO:
 #endif
   default:
-    return nullptr;
+    return translatedString(Tr->TipTypeAuto);
     break;
   }
 }
+#endif /* TIP_TYPE_SUPPORT */
+
 // Returns the resistance for the current tip selected by the user or 0 for auto
+#ifdef TIP_TYPE_SUPPORT
 uint8_t getUserSelectedTipResistance() {
   tipType_t value = (tipType_t)getSettingValue(SettingsOptions::SolderingTipType);
 
@@ -370,3 +372,6 @@ uint8_t getUserSelectedTipResistance() {
     break;
   }
 }
+#else
+uint8_t getUserSelectedTipResistance() { return tipType_t::TIP_TYPE_AUTO; }
+#endif /* TIP_TYPE_SUPPORT */

source/Core/Src/settingsGUI.cpp

@@ -116,8 +116,10 @@ static bool showHallEffect(void);
 #endif /* HALL_SENSOR */
 
 // Tip type selection
+#ifdef TIP_TYPE_SUPPORT
 static void displaySolderingTipType(void);
 static bool showSolderingTipType(void);
+#endif /* TIP_TYPE_SUPPORT */
 
 // Menu functions
 
@@ -267,12 +269,12 @@ const menuitem powerMenu[] = {
 
 const menuitem solderingMenu[] = {
   /*
-   *  Tip Type
    *  Boost Mode Temp
    *  Auto Start
    *  Temp Change Short Step
    *  Temp Change Long Step
    *  Locking Mode
+   *  Tip Type
    *  Profile Phases
    *  Profile Preheat Temperature
    *  Profile Preheat Max Temperature Change Per Second
@@ -288,8 +290,6 @@ const menuitem solderingMenu[] = {
    *  Profile Phase 5 Duration (s)
    *  Profile Cooldown Max Temperature Change Per Second
    */
-  /* Tip Type */
-  {SETTINGS_DESC(SettingsItemIndex::SolderingTipType), nullptr, displaySolderingTipType, showSolderingTipType, SettingsOptions::SolderingTipType, SettingsItemIndex::SolderingTipType, 5},
   /* Boost Temp */
   {SETTINGS_DESC(SettingsItemIndex::BoostTemperature), setBoostTemp, displayBoostTemp, nullptr, SettingsOptions::BoostTemp, SettingsItemIndex::BoostTemperature, 5},
   /* Auto start */
@@ -300,6 +300,10 @@ const menuitem solderingMenu[] = {
   {SETTINGS_DESC(SettingsItemIndex::TempChangeLongStep), nullptr, displayTempChangeLongStep, nullptr, SettingsOptions::TempChangeLongStep, SettingsItemIndex::TempChangeLongStep, 6},
   /* Locking Mode */
   {SETTINGS_DESC(SettingsItemIndex::LockingMode), nullptr, displayLockingMode, nullptr, SettingsOptions::LockingMode, SettingsItemIndex::LockingMode, 7},
+#ifdef TIP_TYPE_SUPPORT
+  /* Tip Type */
+  {SETTINGS_DESC(SettingsItemIndex::SolderingTipType), nullptr, displaySolderingTipType, showSolderingTipType, SettingsOptions::SolderingTipType, SettingsItemIndex::SolderingTipType, 5},
+#endif /* TIP_TYPE_SUPPORT */
 #ifdef PROFILE_SUPPORT
   /* Profile Phases */
   {SETTINGS_DESC(SettingsItemIndex::ProfilePhases), nullptr, displayProfilePhases, nullptr, SettingsOptions::ProfilePhases, SettingsItemIndex::ProfilePhases, 7},
@@ -763,12 +767,16 @@ static void displayHallEffectSleepTime(void) {
   }
 }
 #endif /* HALL_SENSOR */
+
+#ifdef TIP_TYPE_SUPPORT
 static void displaySolderingTipType(void) {
   // TODO wrapping X value
   OLED::print(lookupTipName(), FontStyle::SMALL, 255, OLED::getCursorX());
 }
 // If there is no detection, and no options, max is 0
 static bool showSolderingTipType(void) { return tipType_t::TIP_TYPE_MAX != 0; }
+#endif /* TIP_TYPE_SUPPORT */
+
 static void setTempF(const enum SettingsOptions option) {
   uint16_t Temp = getSettingValue(option);
   if (getSettingValue(SettingsOptions::TemperatureInF)) {

source/Core/Threads/PIDThread.cpp

@@ -30,7 +30,7 @@ int32_t                    powerSupplyWattageLimit = 0;
 bool                       heaterThermalRunaway    = false;
 
 static int32_t getPIDResultX10Watts(TemperatureType_t set_point, TemperatureType_t current_value);
-static void    detectThermalRunaway(const TemperatureType_t currentTipTempInC, const TemperatureType_t tError);
+static void    detectThermalRunaway(const TemperatureType_t currentTipTempInC, const uint32_t x10WattsOut);
 static void    setOutputx10WattsViaFilters(int32_t x10Watts);
 static int32_t getX10WattageLimits();
 
@@ -92,8 +92,8 @@ void startPIDTask(void const *argument __unused) {
           PIDTempTarget = TipThermoModel::getTipMaxInC();
         }
 
-        detectThermalRunaway(currentTipTempInC, PIDTempTarget - currentTipTempInC);
         x10WattsOut = getPIDResultX10Watts(PIDTempTarget, currentTipTempInC);
+        detectThermalRunaway(currentTipTempInC, x10WattsOut);
       } else {
         detectThermalRunaway(currentTipTempInC, 0);
       }
@@ -228,31 +228,59 @@ int32_t getPIDResultX10Watts(TemperatureType_t set_point, TemperatureType_t curr
 #endif
 }
 
-void detectThermalRunaway(const TemperatureType_t currentTipTempInC, const TemperatureType_t tError) {
-  static TemperatureType_t tipTempCRunawayTemp   = 0;
-  static TickType_t        runawaylastChangeTime = 0;
+/*
+ * Detection of thermal runaway
+ * The goal of this is to handle cases where something has gone wrong
+ * 1. The tip MOSFET is broken, so power is being constantly applied to the tip
+ * a. This can show as temp being stuck at max
+ * b. Or temp rising when the heater is off
+ * 2. Broken temperature sense
+ * a. Temp is stuck at a value
+ * These boil down to either a constantly rising temperature or a temperature that is stuck at a value
+ * These are both covered; but looking at the eye/delta between min and max temp seen
+ */
+void detectThermalRunaway(const TemperatureType_t currentTipTempInC, const uint32_t x10WattsOut) {
 
-  // Check for thermal runaway, where it has been x seconds with negligible (y) temp rise
-  // While trying to actively heat
+  static TemperatureType_t tiptempMin         = 0xFFFF; // Min tip temp seen
+  static TemperatureType_t tipTempMax         = 0;      // Max tip temp seen while heater is on
+  bool                     thisCycleIsHeating = x10WattsOut > 0;
+  static TickType_t        heatCycleStart     = 0;
 
-  // If we are more than 20C below the setpoint
-  if ((tError > THERMAL_RUNAWAY_TEMP_C)) {
+  static bool haveSeenDelta = false;
 
-    // If we have heated up by more than 20C since last sample point, snapshot time and tip temp
-    TemperatureType_t delta = currentTipTempInC - tipTempCRunawayTemp;
-    if (delta > THERMAL_RUNAWAY_TEMP_C) {
-      // We have heated up more than the threshold, reset the timer
-      tipTempCRunawayTemp   = currentTipTempInC;
-      runawaylastChangeTime = xTaskGetTickCount();
-    } else {
-      if ((xTaskGetTickCount() - runawaylastChangeTime) > (THERMAL_RUNAWAY_TIME_SEC * TICKS_SECOND)) {
-        // It has taken too long to rise
+  // Check for readings being pegged at the top of the ADC while the heater is off
+  if (!thisCycleIsHeating && (getTipRawTemp(0) > (0x7FFF - 16))) {
+    heaterThermalRunaway = true;
+  }
+
+  if (haveSeenDelta) {
+    return;
+  }
+
+  if (currentTipTempInC < tiptempMin) {
+    tiptempMin = currentTipTempInC;
+  }
+  if (thisCycleIsHeating && currentTipTempInC > tipTempMax) {
+    tipTempMax = currentTipTempInC;
+  }
+  if (thisCycleIsHeating) {
+    if (heatCycleStart == 0) {
+      heatCycleStart = xTaskGetTickCount();
+    }
+  } else {
+    heatCycleStart = 0;
+  }
+
+  if ((xTaskGetTickCount() - heatCycleStart) > (THERMAL_RUNAWAY_TIME_SEC * TICKS_SECOND)) {
+    if (tipTempMax > tiptempMin) {
+      // Have been heating for min seconds, check if the delta is large enough
+      TemperatureType_t delta = tipTempMax - tiptempMin;
+      haveSeenDelta           = true;
+
+      if (delta < THERMAL_RUNAWAY_TEMP_C) {
         heaterThermalRunaway = true;
       }
     }
-  } else {
-    tipTempCRunawayTemp   = currentTipTempInC;
-    runawaylastChangeTime = xTaskGetTickCount();
   }
 }
 
@@ -308,4 +336,4 @@ void setOutputx10WattsViaFilters(int32_t x10WattsOut) {
 #endif
   setTipX10Watts(x10WattsOut);
   resetWatchdog();
-}
+}

source/Core/Threads/UI/logic/OperatingModes.h

@@ -29,20 +29,20 @@ extern "C" {
 #endif
 
 enum class OperatingMode {
-  StartupLogo = 0,    // Showing the startup logo
-  CJCCalibration,     // Cold Junction Calibration
-  StartupWarnings,    // Startup checks and warnings
-  InitialisationDone, // Special state we use just before we to home screen at first startup. Allows jumping to extra startup states
-  HomeScreen,         // Home/Idle screen that is the main launchpad to other modes
-  Soldering,          // Main soldering operating mode
-  SolderingProfile,   // Soldering by following a profile, used for reflow for example
-  Sleeping,           // Sleep state holds iron at lower sleep temp
-  Hibernating,        // Like sleeping but keeps heater fully off until woken
-  SettingsMenu,       // Settings Menu
-  DebugMenuReadout,   // Debug metrics
-  TemperatureAdjust,  // Set point temperature adjustment
-  UsbPDDebug,         // USB PD debugging information
-  ThermalRunaway,     // Thermal Runaway warning state.
+  StartupLogo=10,        // Showing the startup logo
+  CJCCalibration=11,     // Cold Junction Calibration
+  StartupWarnings=12,    // Startup checks and warnings
+  InitialisationDone=13, // Special state we use just before we to home screen at first startup. Allows jumping to extra startup states
+  HomeScreen=0,         // Home/Idle screen that is the main launchpad to other modes
+  Soldering=1,          // Main soldering operating mode
+  SolderingProfile=6,   // Soldering by following a profile, used for reflow for example
+  Sleeping=3,           // Sleep state holds iron at lower sleep temp
+  Hibernating=14,       // Like sleeping but keeps heater fully off until woken
+  SettingsMenu=4,       // Settings Menu
+  DebugMenuReadout=5,   // Debug metrics
+  TemperatureAdjust=7,  // Set point temperature adjustment
+  UsbPDDebug=8,         // USB PD debugging information
+  ThermalRunaway=9,     // Thermal Runaway warning state.
 };
 
 enum class TransitionAnimation {

source/Core/Threads/UI/logic/Soldering.cpp

@@ -138,9 +138,7 @@ OperatingMode gui_solderingMode(const ButtonState buttons, guiContext *cxt) {
 
   // Draw in the screen details
   if (getSettingValue(SettingsOptions::DetailedSoldering)) {
-
     ui_draw_soldering_power_status(cxt->scratch_state.state2);
-
   } else {
     ui_draw_soldering_basic_status(cxt->scratch_state.state2);
   }